METHOD OF MAKING A THREE DIMENSIONAL HORIZONTAL COIL STRUCTURE WITHIN A MOLD COMPOUND PACKAGE HAVING AT LEAST ONE INTEGRATED CIRCUIT CHIP

Description

BACKGROUND

Field

[0001] Integrated circuit packaging.

Description of Related Art

[0002] Demands for higher levels of integration and lower cost drive the integration of components such as system in package "SiP" solutions. Decreases in size and cost and increases in functionality are principle drivers in this regard.

[0003] A method of integrating three dimensional structures within mold compound according to the preamble of claim 1 is known from JP 2009 099752 A. Further prior art methods are disclosed in US 8 822 268 B1, US 2011/068459 A1 and US 2004/197493 A1.

Summary of Invention

[0004] The present invention is defined in method claim 1. In the following description, any embodiment referred to and not falling within the scope of the independent method claim 1 is merely an example useful to the understanding of the invention. In particular, methods falling within the scope of the claimed invention will be described with reference to Figures 7-12. Figures 1-6 and 13-22 relate to examples which do not fall within the scope of the claimed invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] 

Figure 1 shows a cross-sectional side view of a sacrificial carrier including an adhesive layer and contact points on the adhesive layer.

Figure 2 shows the structure of Figure 1 following the formation of the passive structures on the adhesive layer and connected to the contact points.

Figure 3 shows the structure of Figure 2 following the introduction of two integrated circuit chips on the adhesive layer.

Figure 4 shows the structure of Figure 3 following the introduction of a molding material on the adhesive layer to embed the passive structures and the integrated circuit chips.

Figure 5 shows the structure of Figure 4 following the release of the structures embedded in molding material from the carrier.

Figure 6 shows the structure of Figure 5 following additional wafer level processing to include a metallization layer and contact points and placement of solder connections on the contact points.

Figure 7 shows an integrated circuit chip connected to contact points on a substrate in a flip chip configuration.

Figure 8 shows the structure of Figure 7 following the introduction of powder material on the substrate and a build-up or additive process of forming a passive structure.

Figure 9 shows the structure of Figure 8 following the completion of a passive structure by an additive or build-up process.

Figure 10 shows the structure of Figure 9 following the removal of the powder that was not melted by electromagnetic radiation to form the passive structure.

Figure 11 shows the structure of Figure 10 following the introduction of molding material onto a surface of substrate to embed the integrated circuit chip and the passive structure in the molding material.

Figure 12 shows the structure of Figure 11 following the introduction of solder connections to the contact points on a second side of the substrate.

Figure 13 shows a package integrating an integrated circuit chip and a passive structure of a vertical coil.

Figure 14 shows a package structure integrating an integrated circuit chip and coils in a multi-coil configuration in side-by-side multi-coil.

Figure 15 shows a package substrate an integrated circuit chip and coils in a multiple wound coil horizontal configuration.

Figure 16 shows a package structure multiple wound coil vertical configuration.

Figure 17 shows a package structure integrating an integrated circuit chip with passive coils in a side-by-side multi-coil configuration with a core of, for example, a magnetic material disposed between the coils.

Figure 18 shows a package structure integrating an integrated circuit chip and passive coils in a vertical multiple wound coil configuration having a core of a magnetic material there through and coils in a horizontal multiple wound coil configuration having a magnetic core here through.

Figure 19 shows a package substrate integrating an integrated circuit chip and passive structures each of an interconnect, notably a through mold conductive via of, for example, a copper material.

Figure 20 shows a package substrate integrating an integrated circuit chip with a passive structure of a grounded shield.

Figure 21 shows a package substrate integrating an integrated circuit chip with a passive structure of an antenna.

Figure 22 illustrates an embodiment of a computing device.

DETAILED DESCRIPTION

[0006] A method of integrating passive components and an active circuit component such as an integrated circuit chip or chips in a package is described. An active circuit component is any type of circuit component with an ability to electrically control electron flow. A passive component or structure in this context is a component or structure that is not capable of controlling current by means of an electrical signal. Examples of a passive component or structure include a resistor, a capacitor, an inductor, a filter, a balun, a transceiver, a receiver and/or an interconnect, an antenna and a shield. In one embodiment, a method includes forming a passive component or structure on a substrate and introducing one or more active circuit components (e.g., one or more integrated circuit chips) on the substrate followed by the introduction of a molding compound on the at least one passive structure and the one or more active components. In one embodiment, the forming of the passive structure on a substrate is through a build up process or additive process. Representatively, a three-dimensional additive process (e.g., three-dimensional printing process) is used to generate passive structures. Representative of a three-dimensional additive process is a selective melting or sintering processes such as selective laser melting systems or a stereolithography process where, for example, a liquid photopolymer is exposed to electromagnetic energy to selectively solidify the liquid. By building passive structures in a build up or additive process (e.g., layer-by-layer) before or during a packaging process, simple or complex three-dimensional structures like coils, antennas, resistors, or shields can be created. In addition, an entire package volume can be used to place and create additional components which enlarge the functionality and/or the performance of a package module. By employing a method that makes an entire package volume available for active and passive structures, it is further possible to improve the electrical properties of the passive structures in a way that two-dimensional passive structures could not achieve. Finally, by implementing passive components or structures within a complete volume of a package, the footprint of the package can comparatively be made smaller relative to a package with such passive structures mounted side-by-side on a printed circuit board.

[0007] Figures 1-6 illustrate an example of a process flow for the generation of a package including the integration of at least one passive structure and one or more active circuit components (e.g., one or more integrated circuit chips) embedded in a volume of a package. The example illustrated in Figures 1-6 is not part of the invention. The process flow, in this example, employs a fan-out wafer level bonding technique and the passive structure embedded in the ultimate package is a coil. Figure 1 shows a cross-sectional side view of a sacrificial carrier. Carrier 110 is, for example, a metal, polymer or ceramic material having a representative thickness sufficient to provide functionality for the next process operations (e.g., a thickness on the order of millimeters). Disposed on a surface of carrier 110 of structure 100 (an upper surface as viewed) is adhesive layer 115. In one example, adhesive layer 115 is a double-sided adhesive foil laminated to carrier 110. Disposed on adhesive layer 115, in one example, are optional contact points such as metal pads/landings for devices to be formed on the structure.

[0008] Figure 2 shows the structure of Figure 1 following the formation of passive structures on adhesive layer 115 and, in this example, connected to contact points 120. In one example, passive structure 130A, passive structure 130B and passive structure 130C are each three-dimensional passive structures formed by a build-up or additive process (e.g., a three-dimensional printing process). Figure 2 shows passive structure 130A and passive structure 130B as horizontally disposed coils and passive structure 130C is a vertically disposed coil. It is appreciated that coils are one example of a structure that may be built by a build-up or additive process such the 3D printing process. Other structures include other passive structures that are contemplated.

[0009] Figure 3 shows the structure of Figure 2 following the introduction of two integrated circuit chips to the structure. Figure 3 shows integrated circuit chip 140A and integrated circuit chip 140B attached to adhesive layer 115. Integrated circuit chip 140A and integrated circuit chip 140B are disposed on areas of adhesive layer 115 not occupied by (e.g., between) passive structures 130A-130C. Figure 3 specifically shows integrated circuit chip 140A disposed between passive structure 130A and passive structure 130C and integrated circuit chip 140B disposed between integrated circuit chip 130B and integrated circuit chip 130C. In one example, each of integrated circuit chip 140A and integrated circuit chip 140B are disposed with a device side toward adhesive layer 115 (device side down as viewed). In another example, multiple chips or die can be placed between the passive structures 130A and 130B and/or 130B and 130C.

[0010] Figure 4 shows the structure of Figure 3 following the introduction of a molding material on the adhesive layer to embed the passive structures and the integrated circuit chips thereon. Figure 4 shows molding material 150 disposed on adhesive layer 115 and introduced to a thickness to embed passive structures 130A-130C and integrated circuit chip 140A-140B. In one example, a suitable material for molding material 150 is a mold compound such as KE-G1250FC-20CU or a filled epoxy based mold compound.

[0011] Figure 5 shows the structure of Figure 4 following the release of the structures embedded in molding material 150 from the carrier. In one example, the carrier is released (separated) by the addition of thermal, chemical or any other form of energy. Figure 5 shows structure 100 including passive structures 130A-130C and integrated circuit chips 140A-140B embedded in molding material 150 following the release of substrate 110 and adhesive layer 115.

[0012] Figure 6 shows the structure of Figure 5 following additional wafer level processing. Such processing includes, representatively, cleaning the exposed surface (the surface exposed by the release of carrier 110; introduction of dielectric layer 160 of, for example, polyimide, epoxy, polybenzoxazole, blends or similar materials; forming openings or vias to contact points of the chips or passive structures; seeding and plating and patterning redistribution layer 170 and introduction of solder stop material 180. Figure 6 also shows solder connections (solder balls) printed or placed as preformed balls to contact points of redistribution layer 190.

[0013] Figures 7-12 show an embodiment of a process flow for the incorporation of three-dimensional passive structures with one or integrated circuit chips for a flip chip package. Figure 7 shows an integrated circuit chip such as a microprocessor connected to contact points or of a substrate (package or board) in a flip chip configuration. Structure 200 includes substrate 210 that is, for example, a coreless or a substrate with a core structure, but can also be a molded interconnect substrate (MIS) or a ceramic substrate. Substrate 210 includes contact points 220 on a first side and contact points 225 on an opposite second side. Disposed on substrate 210 and in contact with contact points 220 is integrated circuit chip 230. Chip 230 is connected to contact points 220 on substrate 210 through, in one embodiment, solder connections (solder bumps) or copper pillars. Such chip may be attached by mass reflow or compression bonding. In a flip chip configuration, chip 230 is attached to substrate 210 with a device side down or toward substrate 210. The connection of integrated circuit chip 230 to substrate 210 may be underfilled. Figure 7 shows underfilled material 235 of, for example, a polymer material.

[0014] Figure 8 shows the structure of Figure 7 following the introduction of powder material on substrate 210 in an area adjacent integrated circuit chip 203 and a build-up or additive process of forming a passive structure. Referring to Figure 8, in the claimed method, a passive structure is formed by successively introducing a powder material (material particles) and using selective electromagnetic radiation melting principles to heat the powder and melt (sinter) the powder where desired. Figure 8 shows powder 240 that is introduced on substrate 210 one layer at a time. Representatively, such introduction may be done by displacing powder (e.g., electrically conductive particles) from a powder source with a roller aligned with a surface of substrate 210. Once one layer of powder is introduced, an electromagnetic source is activated and electromagnetic radiation imparted onto the powder where desired. Figure 8 shows electromagnetic source 250 including scanner 255 imparting electromagnetic radiation 260 onto desired particles of powder material 240. Scanner 255, in one embodiment, is controlled by a controller including non-transitory machine readable instructions that when executed cause the movement of scanner 255 in at least a two-dimensional plane (x- and y-direction) over an area of substrate 210 containing the powder and to impact electromagnetic radiation at predetermined locations.

[0015] Figure 9 shows the structure of Figure 8 following the completion of the introduction and melting of powder 240 to form a passive structure. Figure 9 shows passive structure 245 of a horizontal coil. As illustrated in Figure 9, the horizontal coil and integrated circuit chip 230 are embedded or surrounded by powder 240.

[0016] Figure 10 shows the structure of Figure 9 following the removal of powder 240 that was not melted by electromagnetic radiation to form the passive structure. Figure 10 shows passive structure 245 of a horizontal coil disposed on substrate 210 and connected to contact points 220 on a surface thereof (electrically connected to substrate 210). Figure 11 shows the structure of Figure 10 following the introduction of molding or glob top material onto a surface of substrate 210 to embed integrated circuit chip 230 and passive structure 245 in the molding material.

[0017] Figure 12 shows the structure of Figure 11 following the introduction of solder connections to contact points 225 on a second side of substrate 210. Figure 12 shows solder connections (solder bumps) 260 connected to contact points 225.

[0018] In the above method, a passive structure was formed on a package substrate following the introduction or placement of a chip on the substrate. In another method, which falls within the scope of the claimed method, the passive structure may be formed prior to the placement or introduction of a chip onto a package substrate.

[0019] Figures 13-21 show different examples of passive structures integrated into a package with one or more integrated circuit chips. The examples shown in Figures 13-21 are not part of the invention. A flip chip package is used as an example to illustrate the various passive structures. Figure 13 shows package 300 integrating integrated circuit chip 330 and passive structure 345 of a vertical coil. Figure 14 shows package structure 400 integrating integrated circuit chip 430 and coil 445A and 445B in a multi-coil configuration in a side-by-side multi-coil configuration. Figure 15 shows package substrate 500 integrating integrated circuit chip 530 and coil 545A and coil 545B in a multiple wound coil horizontal configuration. Figure 16 shows package structure 600 integrating integrated circuit chip 630 and coil 645A and coil 645B in a multiple wound coil vertical configuration.

[0020] Figure 17 shows package structure 700 integrating integrated circuit chip 730 with passive coil 745A and passive coil 745B in a side-by-side multi-coil configuration with core 750 of, for example, a magnetic material disposed between the coils. Figure 18 shows package structure 800 integrating integrated circuit chip 830 and passive coil 845A and passive coil 845B in a vertical multiple wound coil configuration having core 850A of a magnetic material therethrough and coil 845C and coil 845D in a horizontal multiple wound coil configuration having magnetic core 850B therethrough.

[0021] Figure 19 shows package substrate 900 integrating integrated circuit chip 930 and passive structure 945A, passive structure 945B and passive structure 945C each of an interconnect, notably a through mold conductive via of, for example, a copper material. Such through mold vias may individually be connected to contact points on substrate 910.

[0022] Figure 20 shows package substrate 1000 integrating integrated circuit chip 1030 with passive structure 1045 of a grounded shield.

[0023] Figure 21 shows package substrate 1100 integrating integrated circuit chip 1130 with passive structure 1145 of an antenna.

[0024] Figure 22 illustrates computing device 1200 in accordance with one implementation. Computing device 1200 houses board 1202. Board 1202 may include a number of components, including but not limited to processor 1204 and at least one communication chip 1206. Processor 1204 is physically and electrically coupled to board 1202. In some implementations at least one communication chip 1206 is also physically and electrically coupled to board 1202. In further implementations, communication chip 1206 is part of processor 1204.

[0025] Depending on its applications, computing device 1200 may include other components that may or may not be physically and electrically coupled to board 1202. These other components include, but are not limited to, volatile memory (e.g., DRAM), non-volatile memory (e.g., ROM), flash memory, a graphics processor, a digital signal processor, a crypto processor, a chipset, an antenna, a display, a touchscreen display, a touchscreen controller, a battery, an audio codec, a video codec, a power amplifier, a global positioning system (GPS) device, a compass, an accelerometer, a gyroscope, a speaker, a camera, and a mass storage device (such as hard disk drive, compact disk (CD), digital versatile disk (DVD), and so forth).

[0026] Communication chip 1206 enables wireless communications for the transfer of data to and from computing device 1200. The term "wireless" and its derivatives may be used to describe circuits, devices, systems, methods, techniques, communications channels, etc., that may communicate data through the use of modulated electromagnetic radiation through a non-solid medium. The term does not imply that the associated devices do not contain any wires, although in some examples they might not. Communication chip 1206 may implement any of a number of wireless standards or protocols, including but not limited to Wi-Fi (IEEE 802.11 family), WiMAX (IEEE 802.16 family), IEEE 802.20, long term evolution (LTE), Ev-DO, HSPA+, HSDPA+, HSUPA+, EDGE, GSM, GPRS, CDMA, TDMA, DECT, Bluetooth, derivatives thereof, as well as any other wireless protocols that are designated as 3G, 4G, 5G, and beyond. Computing device 1200 may include a plurality of communication chips 1206. For instance, first communication chip 1206 may be dedicated to shorter range wireless communications such as Wi-Fi and Bluetooth and second communication chip 1206 may be dedicated to longer range wireless communications such as GPS, EDGE, GPRS, CDMA, WiMAX, LTE, Ev-DO, and others.

[0027] Processor 1204 of computing device 1200 includes an integrated circuit die packaged within processor 1204. The term "processor" may refer to any device or portion of a device that processes electronic data from registers and/or memory to transform that electronic data into other electronic data that may be stored in registers and/or memory. In some implementations, an integrated circuit die may be integrated with a passive structure in a package in accordance with the teachings described above.

[0028] Communication chip 1206 also includes an integrated circuit die packaged within communication chip 1206. In some implementations, an integrated circuit die may be integrated with a passive structure in a package in accordance with the teachings described above.

[0029] In further implementations, another component housed within computing device 1200 may contain an integrated circuit die that includes one or more devices, such as transistors or metal interconnects. In some implementations, an integrated circuit die may be integrated with a passive structure in a package in accordance with the teachings described above.

[0030] In various implementations, computing device 1200 may be a laptop, a netbook, a notebook, an ultrabook, a smartphone, a tablet, a personal digital assistant (PDA), an ultra mobile PC, a mobile phone, a desktop computer, a server, a printer, a scanner, a monitor, a set-top box, an entertainment control unit, a digital camera, a portable music player, or a digital video recorder. In further implementations, computing device 1200 may be any other electronic device that processes data.

[0031] The above description of illustrated implementations, including what is described in the Abstract, is not intended to be exhaustive or to limit the invention to the precise forms disclosed. While specific implementations of, and examples for, the invention are described herein for illustrative purposes, various equivalent modifications are possible within the scope, as those skilled in the relevant art will recognize.

[0032] These modifications may be made to the invention in light of the above detailed description. The terms used in the following claim should not be construed to limit the invention to the specific implementations disclosed in the specification and the claim. Rather, the scope is to be determined entirely by the following claim, which is to be construed in accordance with established doctrines of claim interpretation.

Claims

1. A method comprising:
forming at least one passive structure (245) on a substrate (210) by a build-up process, wherein forming the at least one passive structure (245) on the substrate (210) comprises coupling the at least one passive structure (245) to respective one or more contact points (220) of the substrate (210), wherein the at least one passive structure (245) comprises a horizontal coil;

introducing one or more integrated circuit chips (230) on the substrate (210), wherein introducing the one or more chips (230) comprises coupling contact points of the one or more chips (230) to contact points (220) of the substrate (210), wherein the one or more chips (230) are coupled to the substrate (210) through solder connections or copper pillars; and

introducing a molding compound on the at least one passive structure (245) and the one or more integrated circuit chips (230);

characterized in that the build-up process comprises repeatedly depositing a layer of conductive powder (240) on the substrate (210) and selectively melting the conductive powder (240) in the deposited layer by electromagnetic radiation and removing the powder (240) that was not melted by electromagnetic radiation.

Ansprüche

1. Ein Verfahren, das folgende Schritte umfasst:

Ausbilden mindestens einer passiven Struktur (245) auf einem Substrat (210) durch einen Aufbauprozess, wobei das Ausbilden der mindestens einen passiven Struktur (245) auf dem Substrat (210) das Koppeln der mindestens einen passiven Struktur (245) mit jeweiligen einem oder mehreren Kontaktpunkten (220) des Substrats (210) umfasst, wobei die mindestens eine passive Struktur (245) eine horizontale Spule umfasst;

Einbringen eines oder mehrerer integrierter Schaltungschips (230) auf das Substrat (210), wobei das Einbringen des einen oder der mehreren Chips (230) das Koppeln von Kontaktpunkten des einen oder der mehreren Chips (230) mit Kontaktpunkten (220) des Substrats (210) umfasst, wobei der eine oder die mehreren Chips (230) durch Lötverbindungen oder Kupfersäulen mit dem Substrat (210) gekoppelt sind; und

Einbringen einer Vergussmasse auf die mindestens eine passive Struktur (245) und den einen oder die mehreren integrierten Schaltungschips (230);

dadurch gekennzeichnet, dass der Aufbauprozess das wiederholte Aufbringen einer Schicht aus leitfähigem Pulver (240) auf dem Substrat (210) und selektives Schmelzen des leitfähigen Pulvers (240) in der abgeschiedenen Schicht durch elektromagnetische Strahlung und Entfernen des nicht geschmolzenen Pulvers (240) durch elektromagnetische Strahlung umfasst.

Revendications

1. Un procédé comprenant :

le fait de former au moins une structure passive (245) sur un substrat (210) par un processus de construction, la formation de ladite au moins une structure passive (245) sur le substrat (210) comprenant le fait de lier ladite au moins une structure passive (245) à un ou plusieurs points de contact respectifs (220) du substrat (210), ladite au moins une structure passive (245) comprenant une bobine horizontale ;

le fait d'introduire une ou plusieurs puces de circuit intégré (230) sur le substrat (210), l'introduction desdites une ou plusieurs puces (230) comprenant le fait de lier les points de contact desdites une ou plusieurs puces (230) à des points de contact (220) du substrat (210), lesdites une ou plusieurs puces (230) étant reliées au substrat (210) par des connexions de soudure ou des piliers en cuivre ; et

le fait d'introduire un composé de moulage sur ladite au moins une structure passive (245) et lesdites une ou plusieurs puces de circuit intégré (230) ;

caractérisé en ce que le processus de construction comprend le fait de déposer de façon répétée une couche de poudre conductrice (240) sur le substrat (210) et de fusionner de façon sélective la poudre conductrice (240) dans la couche déposée par rayonnement électromagnétique et d'éliminer la poudre (240) qui n'a pas été fondue par rayonnement électromagnétique.

Drawing